US20040074464A1 - Integrated electrical connectors for fuel injectors - Google Patents
Integrated electrical connectors for fuel injectors Download PDFInfo
- Publication number
- US20040074464A1 US20040074464A1 US10/653,442 US65344203A US2004074464A1 US 20040074464 A1 US20040074464 A1 US 20040074464A1 US 65344203 A US65344203 A US 65344203A US 2004074464 A1 US2004074464 A1 US 2004074464A1
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- Prior art keywords
- frame
- connectors
- set forth
- engine
- ribbons
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D41/00—Electrical control of supply of combustible mixture or its constituents
- F02D41/30—Controlling fuel injection
- F02D41/3005—Details not otherwise provided for
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M51/00—Fuel-injection apparatus characterised by being operated electrically
- F02M51/005—Arrangement of electrical wires and connections, e.g. wire harness, sockets, plugs; Arrangement of electronic control circuits in or on fuel injection apparatus
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02D—CONTROLLING COMBUSTION ENGINES
- F02D2400/00—Control systems adapted for specific engine types; Special features of engine control systems not otherwise provided for; Power supply, connectors or cabling for engine control systems
- F02D2400/21—Engine cover with integrated cabling
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
- H01R25/006—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits the coupling part being secured to apparatus or structure, e.g. duplex wall receptacle
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
- H01R43/24—Assembling by moulding on contact members
Definitions
- This invention relates generally to diesel engines having provision for electrical connections with fuel injectors of the engine.
- Diesel engines are equipped with electronic actuated fuel injectors that meter a fuel mixture into the combustion chambers of the cylinders for operation of the engine.
- each fuel injector assembly is equipped with a solenoid having a threaded tip end disposed within an open space of a rocker housing of the engine.
- the rocker housing is fabricated of cast aluminum and is bolted to the head of the engine.
- the threaded tip end of each injector is connected to an internally threaded lock nut carried at the end of individual electric lead wires which are routed within the rocker housing to locate the lock nut connecting ends adjacent the threaded tip ends of the injectors and tied to the frame at designated locations.
- the wires come together in a common multi-lead connector module which extends through an opening in the rocker housing for connection with a mating multi-lead connector carried at the ends of multiple lead wire of the engine's electrical system for delivering electrical power to the individual solenoids.
- the prior art has improved the distribution of electrical signals by integrating the electrical leads in the valve cover and other components of the engine. Such systems are disclosed in U.S. Pat. Nos. 5,390,648 to Yanase and U.S. Pat. No. 5,771,850 to Okada, as well as U.S. Patent Publication 2002/0139344 A1. However, in case of a malfunction requiring replacement, the entire engine component must be replaced.
- the subject invention provides an electrical module for distributing an electrical signal to the terminals of one of an ignition and a fuel injector device in an engine.
- the invention comprises a self-supporting lead frame with ribbons of electrically conductive material disposed on the frame and a plurality of terminal connectors separate from and movable relative to the frame for being connected to the terminals.
- the module which is separately formed, may be supported on the rocker housing as a one-piece, integrated structure with multiple lead ribbons incorporated into a single piece.
- the module is preferably supported on an upper surface of the rocker housing and carries push-on connectors at the ends of the leads for push-on connection with the threaded terminals of associated fuel injectors of the engine. All that is required to make a connection with the threaded stud terminals of existing fuel injector assemblies of a diesel engine is to simply align and press the push-on connectors extending from the lead frame onto the threaded terminals of the injectors.
- FIG. 1 is a fragmentary perspective view of a diesel engine fitted with a stamped lead frame circuit integrated with a rocker housing and having push-on connectors;
- FIG. 2 is an enlarged fragmentary perspective view showing a connector of the lead circuit of FIG. 1 joined with an associated fuel injector;
- FIG. 3 is an enlarged fragmentary perspective view showing details of the stamped lead frame circuit and associated connectors.
- FIG. 4 is a perspective view of the stamped lead frame circuit of FIGS. 1 through 3.
- a diesel engine generally shown at 10
- a cylinder head generally shown at 12
- a rocker housing generally shown at 14
- the housing 14 is open at its top and bottom and surrounds a number of moving, working parts of the engine, including a plurality of rocker arm assemblies 16 , as is well known in the art.
- the engine 10 has a plurality of piston cylinders (not shown) in which pistons (not shown) reciprocate.
- a combustion chamber (not shown) is defined in the cylinder between the head 12 and top of the piston (not shown) into which fuel is introduced via fuel injectors, generally shown at 18 , that are mounted on the cylinder head 12 and extend into the chambers (not shown).
- the fuel injectors 18 operate in well-known manner by metering fuel into the combustion chamber to effect combustion.
- the fuel injectors 18 are typically controlled by a solenoid 20 or other electronic device which, when energized, controls the operation of the fuel injector 18 .
- Each solenoid 20 or other suitable electrical controller, extends into the cylinder head 12 and is fitted with at least one and preferably a pair of electrical terminals 24 .
- the terminals 24 comprise threaded studs or posts adapted to receive a mating female connector of a power supply.
- electrical power from the electrical system of the engine is supplied to the individual solenoids 20 via a separately formed lead frame module, generally shown at 26 .
- the lead frame module 26 comprises a frame 28 fabricated of a self-supporting plastics material in which stamped metallic lead ribbons 30 are molded in place.
- the engine 10 is shown having six fuel injectors 18 , each having two terminals 24 of reverse or opposite polarity.
- the lead frame module 26 has six sets of metal lead ribbons 30 and a plurality of self-sustaining support portions 31 extend between the frame 28 and the terminal connectors 32 , which, in turn, attach to the terminals 24 of the injectors 18 .
- Each connector 32 has a plastic body 34 molded to the terminal end of each associated support portion 31 . As best shown in FIGS. 2 and 3, each connector body 34 serves two adjacent ones of the terminals 24 .
- Each connector 32 thus has a pair of terminal sockets 36 that are open at the bottom for press-on installation over the pairs of terminals 24 of each injector 18 .
- Within each socket 36 there is a resilient metal connector lead 38 which is coupled electrically to the associated lead traces 30 and configured to engage and grip the respective terminals 24 .
- the connector leads 38 each comprise a generally U-shaped insert having opposing spring arms 40 carrying contact fingers or undulations 42 adjacent their free or distal ends.
- the spring arms 40 are disposed on opposite sides of the open bottom of the connector socket 36 and are spaced from the sidewalls of the socket 36 .
- the contact fingers 42 are spaced from one another by a distance less than the diameter of the terminals 24 . Extending the terminals 24 of the injectors 18 into the sockets 36 cause the contact fingers 42 and thus the spring arms 40 to deflect laterally outwardly against a constantly applied inwardly return force applied by the resilient spring arms 40 . With a threaded terminal 24 , the fingers 42 ratchet across the threads and, when fully inserted, are caused to seat within a valley between adjacent threads. The inward gripping action and interference with the threads imparts a constant resistance force against inadvertent disconnection of the connectors 32 from the terminals 24 .
- the same push in-type connection approach could be used with other than a threaded terminal configuration of the injectors 18 .
- the connector leads 38 of the connectors 32 would be appropriately configured to engage and make contact with such a terminal configuration in response to pushing the connection 32 into engagement with the terminal.
- the invention contemplates and incorporates herein by reference any combination of terminal/connector configurations that would enable the two to be electrically connected by pushing then into contact with one another.
- the bendable support portions 31 of the traces 30 support the connectors 32 out away from the body 34 in a stationary, but positionable, i.e., movable relative to the frame 28 , location in response to bending the elastically support portions 31 .
- the traces 30 and support portions 31 may be fabricated of copper, coated copper, aluminum, or the like, depending on the particular requirements of a given application.
- the connector leads 38 may likewise be fabrication of copper, coated copper, aluminum, or the like.
- the lead frame module 26 is fabricated as a separate structure from the rocker housing 14 and has an outline corresponding generally to an upper support surface region of the rocker housing 14 .
- the lead frame module 26 is disposed in overlying relation on the upper surface support portion 44 .
- the support portion 44 is preferably inset from an upper sealing surface 45 to which a cover mounts to the rocker housing 14 to enclose the housing 14 and its components.
- the lead frame module 26 extends through an opening 48 in the rocker housing 14 and terminates in a multi-prong plug or fitting 50 for connection to an incoming power supply of the engine's electrical system (not shown).
- the invention provides an independent electrical module 26 for distributing an electrical signal to the terminals 24 of one of an ignition and a fuel injector device in an engine.
- the module 26 comprises a self-supporting lead frame 28 consisting of an organic polymeric or plastic material with metal ribbons 30 of electrically conductive material (e.g., copper) disposed on the plastic frame 28 .
- Pluralities of terminal connectors 32 are separate from and movable relative to the frame 28 for being connected to the terminals.
- the ribbons 30 continue in a free and self-sustaining support portion 31 between the frame 28 and the terminal connectors 32 .
- the support portions 31 are bendable for allowing movement of the connectors 32 relative to the frame 28 .
- Each of the connectors 32 includes a polymeric body defining at least one terminal socket 36 and an electrical contact 38 in the socket 36 . More specifically, each of the connectors 32 includes a pair of the sockets 36 with one of the electrical contacts 38 in each of the sockets 36 and a pair of the bendable support portions 31 are associated with each connector 32 and are paired with the contacts 38 in the associated sockets 36 .
- a power plug 50 is connected electrically to the ribbons 30 for connection to an engine control.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Fuel-Injection Apparatus (AREA)
Abstract
Description
- This application claims the priority and benefits of provisional application serial No. 60/408,046 filed Sep. 4, 2002
- 1. Field of the Invention
- This invention relates generally to diesel engines having provision for electrical connections with fuel injectors of the engine.
- 2. Description of the Related Art
- Diesel engines are equipped with electronic actuated fuel injectors that meter a fuel mixture into the combustion chambers of the cylinders for operation of the engine. Typically, each fuel injector assembly is equipped with a solenoid having a threaded tip end disposed within an open space of a rocker housing of the engine. The rocker housing is fabricated of cast aluminum and is bolted to the head of the engine. The threaded tip end of each injector is connected to an internally threaded lock nut carried at the end of individual electric lead wires which are routed within the rocker housing to locate the lock nut connecting ends adjacent the threaded tip ends of the injectors and tied to the frame at designated locations. The wires come together in a common multi-lead connector module which extends through an opening in the rocker housing for connection with a mating multi-lead connector carried at the ends of multiple lead wire of the engine's electrical system for delivering electrical power to the individual solenoids. The prior art has improved the distribution of electrical signals by integrating the electrical leads in the valve cover and other components of the engine. Such systems are disclosed in U.S. Pat. Nos. 5,390,648 to Yanase and U.S. Pat. No. 5,771,850 to Okada, as well as U.S. Patent Publication 2002/0139344 A1. However, in case of a malfunction requiring replacement, the entire engine component must be replaced.
- Accordingly, the subject invention provides an electrical module for distributing an electrical signal to the terminals of one of an ignition and a fuel injector device in an engine. The invention comprises a self-supporting lead frame with ribbons of electrically conductive material disposed on the frame and a plurality of terminal connectors separate from and movable relative to the frame for being connected to the terminals.
- The module, which is separately formed, may be supported on the rocker housing as a one-piece, integrated structure with multiple lead ribbons incorporated into a single piece. The module is preferably supported on an upper surface of the rocker housing and carries push-on connectors at the ends of the leads for push-on connection with the threaded terminals of associated fuel injectors of the engine. All that is required to make a connection with the threaded stud terminals of existing fuel injector assemblies of a diesel engine is to simply align and press the push-on connectors extending from the lead frame onto the threaded terminals of the injectors.
- These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein:
- FIG. 1 is a fragmentary perspective view of a diesel engine fitted with a stamped lead frame circuit integrated with a rocker housing and having push-on connectors;
- FIG. 2 is an enlarged fragmentary perspective view showing a connector of the lead circuit of FIG. 1 joined with an associated fuel injector;
- FIG. 3 is an enlarged fragmentary perspective view showing details of the stamped lead frame circuit and associated connectors; and
- FIG. 4 is a perspective view of the stamped lead frame circuit of FIGS. 1 through 3.
- Referring to the drawing, wherein like numerals indicate like parts throughout the views, a diesel engine, generally shown at10, is fitted with a cylinder head, generally shown at 12, onto which a rocker housing, generally shown at 14, is mounted by bolts, or the like. The
housing 14 is open at its top and bottom and surrounds a number of moving, working parts of the engine, including a plurality ofrocker arm assemblies 16, as is well known in the art. Theengine 10 has a plurality of piston cylinders (not shown) in which pistons (not shown) reciprocate. A combustion chamber (not shown) is defined in the cylinder between thehead 12 and top of the piston (not shown) into which fuel is introduced via fuel injectors, generally shown at 18, that are mounted on thecylinder head 12 and extend into the chambers (not shown). Thefuel injectors 18 operate in well-known manner by metering fuel into the combustion chamber to effect combustion. Thefuel injectors 18 are typically controlled by asolenoid 20 or other electronic device which, when energized, controls the operation of thefuel injector 18. Eachsolenoid 20, or other suitable electrical controller, extends into thecylinder head 12 and is fitted with at least one and preferably a pair ofelectrical terminals 24. In the embodiment shown, theterminals 24 comprise threaded studs or posts adapted to receive a mating female connector of a power supply. According to the invention, electrical power from the electrical system of the engine is supplied to theindividual solenoids 20 via a separately formed lead frame module, generally shown at 26. Thelead frame module 26 comprises aframe 28 fabricated of a self-supporting plastics material in which stampedmetallic lead ribbons 30 are molded in place. As illustrated, theengine 10 is shown having sixfuel injectors 18, each having twoterminals 24 of reverse or opposite polarity. Accordingly, thelead frame module 26 has six sets ofmetal lead ribbons 30 and a plurality of self-sustainingsupport portions 31 extend between theframe 28 and theterminal connectors 32, which, in turn, attach to theterminals 24 of theinjectors 18. Eachconnector 32 has aplastic body 34 molded to the terminal end of each associatedsupport portion 31. As best shown in FIGS. 2 and 3, eachconnector body 34 serves two adjacent ones of theterminals 24. Eachconnector 32 thus has a pair ofterminal sockets 36 that are open at the bottom for press-on installation over the pairs ofterminals 24 of eachinjector 18. Within eachsocket 36 there is a resilientmetal connector lead 38 which is coupled electrically to the associatedlead traces 30 and configured to engage and grip therespective terminals 24. The connector leads 38 each comprise a generally U-shaped insert having opposingspring arms 40 carrying contact fingers orundulations 42 adjacent their free or distal ends. Thespring arms 40 are disposed on opposite sides of the open bottom of theconnector socket 36 and are spaced from the sidewalls of thesocket 36. Thecontact fingers 42 are spaced from one another by a distance less than the diameter of theterminals 24. Extending theterminals 24 of theinjectors 18 into thesockets 36 cause thecontact fingers 42 and thus thespring arms 40 to deflect laterally outwardly against a constantly applied inwardly return force applied by theresilient spring arms 40. With a threadedterminal 24, thefingers 42 ratchet across the threads and, when fully inserted, are caused to seat within a valley between adjacent threads. The inward gripping action and interference with the threads imparts a constant resistance force against inadvertent disconnection of theconnectors 32 from theterminals 24. - It will be appreciated that the same push in-type connection approach could be used with other than a threaded terminal configuration of the
injectors 18. For example, if thesolenoid 20 of thefuel injectors 18 were fitted with blade-type terminals, the connector leads 38 of theconnectors 32 would be appropriately configured to engage and make contact with such a terminal configuration in response to pushing theconnection 32 into engagement with the terminal. Accordingly, the invention contemplates and incorporates herein by reference any combination of terminal/connector configurations that would enable the two to be electrically connected by pushing then into contact with one another. - It is to be understood that the
bendable support portions 31 of thetraces 30 support theconnectors 32 out away from thebody 34 in a stationary, but positionable, i.e., movable relative to theframe 28, location in response to bending the elastically supportportions 31. Thetraces 30 andsupport portions 31 may be fabricated of copper, coated copper, aluminum, or the like, depending on the particular requirements of a given application. The connector leads 38 may likewise be fabrication of copper, coated copper, aluminum, or the like. - The
lead frame module 26 is fabricated as a separate structure from therocker housing 14 and has an outline corresponding generally to an upper support surface region of therocker housing 14. Thelead frame module 26 is disposed in overlying relation on the uppersurface support portion 44. Thesupport portion 44 is preferably inset from an upper sealing surface 45 to which a cover mounts to the rocker housing 14 to enclose thehousing 14 and its components. - Additionally, the
lead frame module 26 extends through anopening 48 in therocker housing 14 and terminates in a multi-prong plug or fitting 50 for connection to an incoming power supply of the engine's electrical system (not shown). - Accordingly, the invention provides an independent
electrical module 26 for distributing an electrical signal to theterminals 24 of one of an ignition and a fuel injector device in an engine. Themodule 26 comprises a self-supportinglead frame 28 consisting of an organic polymeric or plastic material withmetal ribbons 30 of electrically conductive material (e.g., copper) disposed on theplastic frame 28. Pluralities ofterminal connectors 32 are separate from and movable relative to theframe 28 for being connected to the terminals. Theribbons 30 continue in a free and self-sustainingsupport portion 31 between theframe 28 and theterminal connectors 32. Thesupport portions 31 are bendable for allowing movement of theconnectors 32 relative to theframe 28. Each of theconnectors 32 includes a polymeric body defining at least oneterminal socket 36 and anelectrical contact 38 in thesocket 36. More specifically, each of theconnectors 32 includes a pair of thesockets 36 with one of theelectrical contacts 38 in each of thesockets 36 and a pair of thebendable support portions 31 are associated with eachconnector 32 and are paired with thecontacts 38 in the associatedsockets 36. - As alluded to above, a
power plug 50 is connected electrically to theribbons 30 for connection to an engine control. - It is to be understood that other embodiments of the invention that accomplish the same function are incorporated herein within the scope of any ultimately allowed patent claims.
Claims (15)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/653,442 US6843217B2 (en) | 2002-09-04 | 2003-09-02 | Integrated electrical connectors for fuel injectors |
Applications Claiming Priority (2)
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US40804602P | 2002-09-04 | 2002-09-04 | |
US10/653,442 US6843217B2 (en) | 2002-09-04 | 2003-09-02 | Integrated electrical connectors for fuel injectors |
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US20040074464A1 true US20040074464A1 (en) | 2004-04-22 |
US6843217B2 US6843217B2 (en) | 2005-01-18 |
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20050217643A1 (en) * | 2004-03-31 | 2005-10-06 | Siemens Aktiengesellschaft | Electrical connection device for injection devices of internal combustion engines |
DE102004049031A1 (en) * | 2004-10-08 | 2006-04-20 | Audi Ag | Motor vehicle with internal combustion engine has setting members for changing lift of gas change valve mounted on outside of engine with at least two electrically contacted through assembly strip |
NL1031232C2 (en) * | 2006-02-24 | 2007-08-27 | Daf Trucks Nv | Internal combustion engine with MID plastic strip including electrical conductors, has runners protruding from annular portion of strip towards cylinder heads |
US20170328320A1 (en) * | 2016-05-11 | 2017-11-16 | Caterpillar Inc. | Fuel injector wiring harness tray |
EP2426341B1 (en) * | 2009-04-30 | 2018-10-31 | Yanmar Co., Ltd. | Engine |
DE102005035072B4 (en) * | 2005-07-27 | 2020-06-18 | Bayerische Motoren Werke Aktiengesellschaft | Combustion piston engine with an electric actuator for stroke actuation of the gas exchange valves |
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US6935315B2 (en) * | 2003-12-30 | 2005-08-30 | International Engine Intellectual Property Company, Llc | High volume actuating fluid rail |
US7341038B1 (en) | 2006-12-15 | 2008-03-11 | Federal - Mogul World Wide, Inc. | Engine cover with embedded leads |
US7334572B1 (en) * | 2007-01-30 | 2008-02-26 | Ford Global Technologies, Llc | System and method for securing fuel injectors |
US7942124B2 (en) * | 2008-03-28 | 2011-05-17 | Harbert Richard H | Exposed coil rocker arm cover assembly having external multi-coil mounting bracket |
JP6232393B2 (en) * | 2015-04-17 | 2017-11-15 | 矢崎総業株式会社 | Circuit arrangement |
US10247150B1 (en) | 2017-04-24 | 2019-04-02 | Brunswick Corporation | Outboard motor powerhead section and fuel delivery system |
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US6341967B1 (en) * | 1999-11-26 | 2002-01-29 | Sumitomo Wiring Systems, Ltd. | Connector block for injector |
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US7290516B2 (en) * | 2004-03-31 | 2007-11-06 | Siemens Aktiengesellschaft | Electrical connection device for injection devices of internal combustion engines |
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US20170328320A1 (en) * | 2016-05-11 | 2017-11-16 | Caterpillar Inc. | Fuel injector wiring harness tray |
US10012191B2 (en) * | 2016-05-11 | 2018-07-03 | Caterpillar Inc. | Fuel injector wiring harness tray |
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